Production of terpenic phenolaldehyde resin



Patented; Febr 941 UNITED STATES PRODUCTION OF TERPENIC PHENOL- ALDEHYDE RESIN Israel Rosenblum, New York,- N. Y.

No Drawing.

8 Claims.

The present invention relates to the production of synthetic resins for use in the manufacture of coating compositions of various kinds, either alone or in conjunction with other synthetic or natural materials,'and more particularly to an improved process for obtaining phenolic resins which are readily soluble in varnish oils, and to the resinous compositions so produced.

. The present application is a continuation-in- 10 part of my copending applications, Serial No.

594,379, filed February 20, 1932, and Serial No.

751,419, filed November 3, 1934, now Patent No.

2,121,642, dated June 21, 1938. r

In a number of my prior applications are described various methods whereby a terpenic material, such as a terpene hydrocarbon and various substitution products of terpene hydrocarbons, are chemically incorporated in a phenol-aldehyde resin whereby not only is the yield of resinous product increased by the amount of relatively inexpensive terpenic material incorporated therein, but oil-solubility is imparted to resins which, in the absence of the terpenic material, would be insoluble or diflicultly soluble in vegetable oils.

By such process, therefore, oil 'soluble resins are obtained having an unusually high proportion of phenol-aldehyde condensate; in' fact, except for the terpenic material, the resin may be composed entirely of phenol and aldehyde condensates.'

nishes, can be obtained by conducting the phenolaldehyde-terpene condensation in two stages. In 45 the first stage the phenol and aldehyde are caused to react in the presence of a relatively mild catalyst to produce an intermediate more or less resinous material. .This initial condensation may or may nottake place in the presence of the ter- 56 penic material which is to be incorporated in the expensive materials and without the aid of rosin Application February 24, 1937, Serial No. 127,518

' resin; or only part of such terpenic material may then be present. After the initial condensation," the catalyst, especially if it is a non-volatile ma terial, may be removed by washing or otherwise, after which further condensation is made to take 5 place in the presence of the terpenic material and of a stronger catalyst. This latter catalyst is preferably aqueous or dry hydrochloric acid which remains in the reaction mass up to about 130 C. and is gradually expelled with increasing 110] temperatures. Acid reacting chlorides may also be employed, such chlorides being removed as by washing with water, before the final heating of the resin to high temperatures (200-250" C.) to

expel volatile uncomblned material. 5

The invention will be illustrated in greater detail in the following examples:

Example 1.An intermediate resin is obtained by the interaction of Parts Butyl phenol 100 40% formaldehyde solution 100 Dipentene 30 Zinc acetate 0.25 to 2 (All parts by weight.)

Themixture is refluxed at the boiling point for about 16 hours, after which the aqueous layer is drawn off and the condensate heated to about 130 C. in order to dehydrate'it. The mixture is then treated with Parts Dipentene Concentrated HCl (sp. gr. 1.19) 65 about 130 C., at whichtemperature hydrogen chloride begins to be eliminated. A moderate 45 current of an inert gas is passed through the i mass to aid the removal of volatile matter. The

heating is continued up to a temperature of about 250C. to expel uncombined volatile material. The yield is about -90% based on the total 0 weight of phenol and dipentene, showing that a large proportion of the dipentene has become chemically bound in the resinous product. The heating is preferably continued until a product is obtained which is solid at room temperature and has an acid number of about 20. The acid number of a butyl phenol resin produced in a manner similar to the above-process, but in the absence of the terpene material, is about 70.

The resin is compatible with drying and nondrying varnish oils, and with synthetic and nat ural resins, and issoluble in the common solvents.

- It is particularly suited for the manufacture of Parts Phenol 94 40% formaldehyde solutionu '75 Dipcntene 22 Zinc acetate 0.25 to 2 The mixture is condensed under reflux or pressure untila soluble resinous condensate is obtained. The water is then drawn off or distilled off at about 110 C. and the intermediate resin is treated with Parts Dipentene '72, Concentrated HCl 100 Toluol 100 The mixture is heated with stirring for about hours at a temperature of about 60 to 70 C. The proportion of formaldehyde to phenol is equimolecular; while the total weight of dipen-tene is equal to that of the phenol. The toluol acts as a diluent to facilitate handling of the viscous mass. After the condensation the mass presents a two-layer system. The lower aqueous layer is drawn off and the upper layer is given one washingwith water. It is then heated gradually to about 250 C. to remove uncombined matter and also the toluol. Hydrogen chloride begins to be expelled at about 130 to 150 C.; while free phenol and dipentene pass over at about 200230- C. A very pale, hard resin is obtained having an acid value of about 25. The yield is about 90% based on the total weight of phenol and dipentene. The resin is soluble in varnish oils and produces quick-drying varnishes of high durability.

Example 3.-Employing the same intermediate resin as is obtained in Example 2, the amount of total dipentene used is increased to 136 parts, so that the proportion of dipentene to phenol is equimolecular. Following the same procedure as in Example 2, a resin is obtained in which again almost all of the dipentene is chemically bound in the phenolic condensate.

In place of the aqueous hydrochloric acid, gaseous hydrogen chloride can be introduced into the reacting mass during the same period of reaction. In general, it will be found that by operating under anhydrous conditions, in which case'solid aldehyde will be employed in place of aqueous aldehyde, better yields and lower acid numbers can be obtained.

The process above-described is applicable with all kinds of phenols, including the higher homologues of phenol and also various substituted phenols and condensation products of phenols, ineluding cresols, amyl and higher phenols, xylenols, paraphenylphenol, ketone-phenol condensates, such as acetone-phenol, various dioxydiphenyldialkylalkanes (methane, propane, etc.) and the like.

The reactions above-described will also take place when other terpenic material is employed in place of all or part of the dipentene, similar oil-soluble and pale resins being obtained. Thus, terpineol, pine oil, borneol, turpentine and other terpene'hydrocarbons and substituted hydrocarbons or mixtures thereof, can be employed with very satisfactory results.

In the formation of the intermediate resin any known catalyst may be employed, preferably a relatively mild catalyst, like zinc acetate; but various other compounds of zinc, of the alkali and alkaline earth metals, and of other metals heretofore employed in the condensation of a phenol and an aldehyde, and also acids of vari ous kinds, may be used. In the second stage of the reaction, however, relatively strong contact agents should be employed, and preferably strongly acid chlorides, including hydrogen chloride, zinc chloride aluminum chloride, silicon tetrachloride, titanium tetrachloride, boron trichloride, etc. all of which are grouped under th expression reactive chloride.'

If desired, the terpenic material'may be absent during the initial condensation of the phenol and aldehyde, in which case a suitable organic solvent is employed.- The total amount of terpenic material'is then added during the second stage of the reaction.

I- claim:

1. A method of producing oil-soluble phenolic resins, which comprises reacting a phenol and formaldehyde in the presence of a relatively mild catalyst and of a terpenic material of the group consisting of. dipentene, turpentine, borneol and terpineol, and continuing the condensation in the .prese'nceof an additional quantity of the terpenic material and of a stronger acidic inorganic chlo ride catalyst until a considerable part of the terpenic material has become chemically bound in the phenol-formaldehyde condensate.

2. The method of producing oil-soluble phenolic resins, which comprises reacting a phenol'and an aldehyde in the presence of-a relatively mild catalyst to the intermediate resinous stage, and then continuing the condensation in the presence of a terpenic material of the group consisting of di- 'dipentene, turpentine, borneol and terpineol, and

subsequently continuing the reaction with the terpenic material athigher temperatures in'the presence of hydrochloric acid.

6. The method of producing oil-soluble resins, which comprises condensing a phenol and formaldehyde in the presence of zinc acetate and a terpenic material of the group consisting of dipentene, turpentine, borneol and terpineol, removing the acetate, adding a further quantity of the terpenic material and continuing the condensation at higher temperatures in the presence of hydrochloric acid.

essence i 3 oi the 'gr'oup consisting of dipentene, turpentine, borneoland terpineol, and of a catalylt. t the intermediate resinous stage, and subsequently adding an acid-reacting inorganic chlcrideto the condensate so-obtained and continuing the reaction with the terpenic material in the presence 10 (if such chloride.

.8. The methodof producing oll-sclnble resins,

which comprises condensin & phenol and tcrmal- 'dehyde in the presence of zinc acetate and dipentene, removing the acetate, adding-a further quantityct the temen c material and continuing 5 l the Zcondensati'on athigher temperctures 'in the presence of hydrochloric scid.

ISRAEL RdsENBLUM. 10 

